Article of footwear having an upper with connectors for attaching to a sole structure

ABSTRACT

An article of footwear includes an upper and a sole structure. The upper includes elongated members extending from a lower peripheral portion that mechanically connect the upper to a sole structure. The sole structure includes several recesses for engaging the elongated members. The upper and/or the elongated members can be printed using a three-dimensional printer.

BACKGROUND

The present embodiments relate generally to articles of footwear, and inparticular to articles of footwear with an upper and sole structure.

Articles of footwear generally include an upper and a sole structure.The upper may be formed from a variety of materials that are stitched(sewn) or adhesively bonded together to form a space or void within thefootwear in order to support and secure a foot. The sole assembly issecured to a lower portion of the upper and is generally positionedbetween the foot and the ground. In many articles of footwear, includingathletic footwear styles, the sole assembly often incorporates aninsole, a midsole, and an outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is an isometric side view of an embodiment of an article offootwear with an upper having various portions;

FIG. 2 is a schematic view of the upper shown in FIG. 1;

FIG. 3 is an exploded view of the embodiment of the article of footwearin FIG. 1 showing the upper, elongated members, and the sole structure;

FIGS. 4 and 5 are enlarged views of an embodiment of an elongatedmember;

FIG. 6 is an isometric view of the embodiment of the sole structure inFIG. 3, further including a cross sectional view of the sole structure;

FIGS. 7-10 are schematic views of steps in a method of connecting anupper to a sole structure, according to an embodiment;

FIG. 11 is an exploded isometric view of an embodiment of an upper and acord element with integrally formed elongated members;

FIG. 12 an isometric side view of an another embodiment of an article offootwear having alternate elongated members;

FIG. 13 is an exploded isometric view of the embodiment in FIG. 12,showing the upper, elongated members, and a sole structure;

FIG. 14 is an isometric view of the sole structure in FIG. 13, with across sectional view of the sole structure;

FIG. 15 is a schematic view of an embodiment of a three-dimensionalprinter;

FIG. 16-17 are schematic views of steps in a method of printing anupper, and printing elongated members onto the upper, according to anembodiment;

FIG. 18 is an isometric view of the upper and elongated members shown inFIGS. 15-17, according to an embodiment; and

FIGS. 19-20 are schematic views of steps in a method of printingmechanical connectors onto an upper, according to an embodiment.

DETAILED DESCRIPTION

Embodiments can include provisions for connecting an upper and a solestructure. In one aspect, an article of footwear includes an upperhaving a lower peripheral portion, where the upper includes an elongatedmember extending from the lower peripheral portion. The article offootwear also includes a sole structure having a top surface and anopposing bottom surface, where the top surface is disposed closer to theupper than is the bottom surface. The sole structure including a recessdisposed in the top surface. The top surface of the sole structurefurther includes an interior portion, and also includes an outerperipheral portion disposed outwardly of the interior portion. Therecess includes a first end portion associated with the outer peripheralportion of the top surface and the recess includes a second end portionassociated with the interior portion of the top surface. The elongatedmember includes a first end portion and the elongated member includes asecond end portion. The first end portion of the elongated memberengages the first end portion of the recess and the second end portionof the elongated member engages the second end portion of the recess.

In another aspect, a method of making an article of footwear includesassociating an upper of the article of footwear with a printer, wherethe upper has a lower peripheral portion. The method also includesprinting a first end portion of a mechanical connector so that the firstend portion of the mechanical connector is coupled with the lowerperipheral portion. The method also includes printing a second endportion of the mechanical connector, where the second end portionextends away from the lower peripheral portion. The second end portionis configured to engage a sole structure and fasten the upper to thesole structure.

In another aspect, a method of printing an upper and an elongated memberwith a printer includes providing the printer capable of printing eachof a first polymeric material and a second polymeric material, where thefirst polymeric material has a density when cured that is less than adensity of the second polymeric material when cured. The method alsoincludes printing the upper with the first polymeric material andprinting the elongated member with the second polymeric material. Theelongated member is configured to mechanically connect the upper to asole structure.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

FIG. 1 illustrates an isometric view of an embodiment of an article offootwear 100, or simply article 100. Although the embodiments throughoutthis detailed description depict articles configured as athleticarticles of footwear, in other embodiments the articles may beconfigured as various other kinds of footwear including, but not limitedto: hiking boots, soccer shoes, football shoes, sneakers, running shoes,cross-training shoes, rugby shoes, basketball shoes, baseball shoes aswell as other kinds of shoes. Moreover, in some embodiments, articlesmay be configured as various kinds of non-sports related footwear,including, but not limited to: slippers, sandals, high heeled footwear,loafers as well as any other kinds of footwear.

Articles are generally made to fit various sizes of feet. In theembodiments shown, the various articles are configured with the samefootwear size. In different embodiments, the articles could beconfigured with any footwear sizes, including any conventional sizes forfootwear known in the art. In some embodiments, an article of footwearmay be designed to fit the feet of a child. In other embodiments, anarticle of footwear may be designed to fit the feet of an adult. Still,in other embodiments, an article of footwear may be designed to fit thefeet of a man or a woman.

In some embodiments, an article of footwear may include an upper and asole structure. In the embodiment shown in FIG. 1, article 100 has upper102 attached to sole structure 110. Sole structure 110 is secured orfastened to an upper and extends between the foot and the ground when anarticle is worn. In different embodiments, sole structure 110 mayinclude different components. For example, sole structure 110 mayinclude an outsole, a midsole, and/or an insole. In some cases, one ormore of these components may be optional.

Sole structure 110 may provide one or more functions for an article. Forexample, in some embodiments, sole structure 110 may be configured toprovide traction for an article. In addition to providing traction, solestructure 110 may attenuate ground reaction forces when compressedbetween the foot and the ground during walking, running or otherambulatory activities. The configuration of sole structure 110 may varysignificantly in different embodiments to include a variety ofconventional or non-conventional structures. In some cases, theconfiguration of sole structure 110 can be selected according to one ormore types of ground surfaces on which sole structure 110 may be used.Examples of ground surfaces include, but are not limited to: naturalturf, synthetic turf, dirt, pavement, as well as other surfaces.

Generally, upper 102 may be any type of upper. In particular, upper 102may have any design, shape, size and/or color. For example, inembodiments where article 100 is a basketball shoe, upper 102 could be ahigh top upper that is shaped to provide high support on an ankle. Inembodiments where article 100 is a running shoe, upper 102 could be alow top upper. In some embodiments, upper 102 could further includeprovisions for fastening article 100 to a foot, such as a hook and looksystem (Velcro, for example) and may include still other provisionsfound in footwear uppers. Also, some embodiments of upper 102 mayinclude leather, synthetic materials (such as plastic or syntheticleather), mesh, or a combination thereon. In FIG. 1, upper 102 is madefrom a printable material dispersed by a three-dimensional printeraccording to a method discussed in further detail below.

Referring to FIG. 1, for purposes of reference, upper 102 may be dividedinto forefoot portion 10, midfoot portion 12 and heel portion 14.Forefoot portion 10 may be generally associated with the toes and jointsconnecting the metatarsals with the phalanges. Midfoot portion 12 may begenerally associated with the metatarsals of a foot. Likewise, heelportion 14 may be generally associated with the heel of a foot,including the calcaneus bone. In addition, upper 102 may include lateralside 16 and medial side 18. In particular, lateral side 16 and medialside 18 may be opposing sides of article 100. Furthermore, both lateralside 16 and medial side 18 may extend through forefoot portion 10,midfoot portion 12 and heel portion 14. It will be understood thatforefoot portion 10, midfoot portion 12 and heel portion 14 are onlyintended for purposes of description and are not intended to demarcateprecise regions of upper 102. Likewise, lateral side 16 and medial side18 (not shown) are intended to represent generally two sides of upper102, rather than precisely demarcating upper 102 into two halves. Asshown in FIG. 1, article of footwear 100 is intended to be used with aright foot; however, it should be understood that the followingdescription may equally apply to a mirror image of article of footwear100 that is intended for use with a left foot (not shown).

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “lateral” as used to indicate a directionthroughout this detailed description and in the claims refers to adirection extending along a width of a component. For example, thelateral direction of upper 102 may extend between medial side 18 andlateral side 16 of upper 102. Additionally, the term “distal” as usedthroughout this detailed description and in the claims refers to adirection directed away from a foot, while the term “proximal” as usedthroughout this detailed description and in the claims refers to adirection directed towards the foot. It will be understood that each ofthese directional adjectives may be applied to individual components ofan article, such as an upper and/or a sole structure.

In some embodiments, upper 102 as shown in FIG. 1 may be made from athree-dimensional printer (discussed in detail later). The term“three-dimensional printer” as used throughout this detailed descriptionand in the claims refers to a printing apparatus capable of printing ordisposing a printable material that forms a three-dimensional object.Printable material could be associated with any color such as red, blue,green, yellow, white, black, or a combination thereof. Printablematerial could also be made of toner material made from acrylic,plastic, ink, or any other polymeric material known in the art forprinting a three-dimensional object from a three-dimensional printer.

In different embodiments, upper 102 may be configured with one or moredesigns in order to achieve a certain look or function. For example, inthe embodiment shown in FIG. 1, upper 102 comprises a mesh structure 103disposed throughout one or more portions of upper 102.

In at least some embodiments, the mesh structure 103 provided for upper102 can vary throughout different portions of upper 102. For example,the embodiment shown in FIG. 1 is configured with several distinctportions, which may each be characterized by a different meshconfiguration. A first portion 109 of upper 102 may extend primarilythrough forefoot portion 10 and midfoot portion 12. A second portion 105of upper 102 may primarily extend through heel portion 14. A thirdportion 106 of upper 102 may primarily extend around opening 114 ofupper 102, where opening 114 is configured to receive a foot. Asindicated schematically in FIG. 1, each of these portions may havedistinct mesh patterns that may vary in mesh size, mesh geometry and/ormaterial properties. As one example, an enlarged view of first portion109 of upper 102 shows that mesh portion 103 comprises a grid ofmaterial surrounding diamond-shaped and/or rectangular openings. It willbe understood that the mesh patterns for each distinct portion of upper102 can be varied to achieve different provisions in different portionsof upper 102. Moreover, while the exemplary embodiment depicts aparticular arrangement of distinct mesh patterns for different portionsof upper 102, other embodiments could include any other configurationsof mesh patterns. In at least some embodiments, for example, a majorityof upper 102 may be comprised of a single mesh pattern. In still otherembodiments, some portions of upper 102 could be comprised of any othernon-mesh materials including various textiles, leather goods or othermaterials known in the art for making uppers.

Upper 102 may further include a tongue portion 104. In some embodiments,tongue portion 104 may be disposed along the throat of upper 102. In atleast some embodiments, tongue portion 104 may comprise a portion thatis substantially more flexible than adjacent portions of upper 102,which may be comprised of mesh structure 103. It is contemplated that inat least some embodiments, tongue portion 104 may facilitate theexpansion of the throat of upper 102 around a foot. In some embodiments,tongue portion 104 may provide tension between opposing sides of upper102 once a foot has been inserted into upper 102, thereby helping tokeep upper 102 fastened around the foot. Tongue portion 104 may alsoprovide cushioning to the top of a foot.

Tongue portion 104 could be made of any material. In some embodiments,for example, tongue portion 104 could be comprised of a stretchablefabric. In other embodiments, tongue portion 104 could have a meshconfiguration.

FIG. 2 illustrates a schematic view of upper 102 in a flattenedconfiguration. In embodiments where upper 102 is formed using athree-dimensional printer, the three-dimensional printer may print, forexample, first portion 109, second portion 105 and third portion 106 ofupper 102. In some cases, the three-dimensional printer could also beused to print tongue portion 104. However, some portions may be printedand others may be joined to the printed portions at a later time. Forexample, in some embodiments, tongue portion 104 could be joined withupper 102 after first portion 109, second portion 105 and third portion106 have been printed.

Upper 102 may then be formed into a three-dimensional structure, asshown in FIGS. 1 and 3, for example, in order to conform to atraditional upper that is shaped to receive a foot. In otherembodiments, upper 102 may be printed as a three-dimensional structuresuch that immediately after upper 102 is formed, upper 102 is configuredto receive a foot. In other words, in at least some embodiments, upper102 could be printed with a three-dimensional geometry, rather thanbeing printed as a two-dimensional layer.

Embodiments can include provisions to attach an upper to a solestructure without the use of adhesives, stitching, sewing, knitting oruse of a strobel. In the embodiments shown in FIG. 3, upper 102 mayattach to sole structure 110 by using a plurality of elongated members200 (also referred to hereafter as simply elongated members 200). In atleast some embodiments, elongated members 200 may be mechanicalconnectors that facilitate the connection of an upper to a solestructure.

FIG. 3 is an exploded view of the embodiment of upper 102 shown in FIG.1, along with elongated members 200 and sole structure 110. Solestructure 110 includes top surface 111 having a plurality of recesses300 (also referred to hereafter as simply recesses 300). Sole structure110 further includes bottom surface 112, which is a surface opposite oftop surface 111. Top surface 111 is disposed closer to upper 102 thanbottom surface 112. Bottom surface 112 is generally intended to contacta ground surface (not shown). Recesses 300 on top surface 111 aregenerally configured to receive elongated members 200. For example,first elongated member 201 may be received by first recess 301.

In the embodiment shown in FIG. 3, upper 102 further includes cordelement 150. Cord element 150 generally extends along a lower peripheralportion 107 of upper 102. The term “lower peripheral portion” as usedthroughout this detailed description and in the claims refers to theouter perimeter of upper 102 when upper 102 is laid flat, and refers tothe lower perimeter of upper 102 adjacent to sole structure 110 whenupper 102 is attached to sole structure 110. Cord element 150 generallyhas a circular cross section with the diameter of the circular crosssection being less than the diameter of apertures 230 of elongatedmembers 200. In other embodiments, cord element 150 could have a squareor rectangular cross section, and accordingly, other embodiments ofapertures 230 of elongated members 200 could be square or rectangular,respectively.

Elongated members 200 may attach to upper 102 by cord element 150passing through apertures 230 of elongated members 200. While cordelement 150 is used to attach elongated members 200 to upper 102 in theexemplary embodiment, in other embodiments, elongated members 200 may beattached directly onto lower peripheral portion 107 of upper 102. Forexample, elongated members 200 could be attached directly to firstportion 109 and/or second portion 105 of upper 102 at lower peripheralportion 107. Further, in other embodiments, elongated members 200 couldbe connected to upper 102 at one or more portions above lower peripheralportion 107.

Also, as shown in FIG. 3, elongated members 200 are generally spacedevenly around lower peripheral portion 107 of upper 102. That is,elongated members 200 may be disposed on forefoot 10 portion, midfootportion 12, and heel portion 14 on both lateral side 16 and the medialside (not shown) of article 100. In other embodiments, elongated members200 may not be evenly spaced around lower peripheral portion 107 ofupper 102. For example, elongated members 200 on forefoot portion 10could be spaced further apart from one another than elongated members200 on midfoot portion 12.

FIGS. 4-6 illustrate the relationship between elongated members 200attached to upper 102 and recesses 300 on sole structure 110. Elongatedmembers 200 include a first elongated member 201. Referring to FIGS. 4and 5, first elongated member 201 includes first end portion 221 andsecond end portion 222. First end portion 221 includes first aperture231. In some embodiments, first end portion 221 has a rounded orring-like geometry that surrounds first aperture 231. In otherembodiments, however, the geometry of first end portion 221 could varyin any other manner.

First aperture 231 may be configured to receive cord element 150 ofupper 102. By cord element 150 extending through first aperture 231 offirst end portion 221, first elongated member 201 is free to at leastpartially rotate around cord element 150. This allows for easieralignment between first elongated member 201 and first recess 301 (seeFIG. 6).

In some embodiments, the exterior appearance of first end portion 221may correspond to the shape of first aperture 231. For example in FIG.4, first aperture 231 is generally round, and accordingly, first endportion 221 is also generally round. In other embodiments, firstaperture 231 could be square or rectangular, and accordingly, first endportion 221 of first elongated member 201 and first end portion 321 offirst recess 301 could also be square or rectangular, respectively. Inother embodiments, the geometry of aperture 231 may not correspond withthe geometry of first end portion 221.

As shown in FIG. 5, first elongated member 201 further includes secondend portion 222. In order to engage first recess 301 (shown in FIG. 6)of recesses 300 and secure upper 102 to sole structure 110, second endportion 222 may include several protrusions on bottom surface 240 ofsecond end portion 222. In some embodiments, second end portion 222could include one protrusion. In other embodiments, second end portion222 could include at least three, four, or five protrusions.

In the exemplary embodiment shown in FIG. 5, second end portion 222includes first protrusion 225 and second protrusion 226. Firstprotrusion 225 and second protrusion 226 generally extend in a distaldirection with respect to bottom surface 240. In other words, firstprotrusion 225 and second protrusion 226 extend away from bottom surface240. Although the embodiment shown in FIG. 5 illustrates firstprotrusion 225 and second protrusion 226 as generally similar, firstprotrusion 225 and second protrusion 226 may have at least somedifferences in other embodiments. Also, as shown in FIG. 5, in theexemplary embodiment, first protrusion 225 and second protrusion 226have a pointed end. For example, first protrusion has first end 227. Inother embodiments, first end 227 could be a flat surface. Still, inother embodiments, first end 227 could be a rounded surface.

To better secure or fasten upper 102 to sole structure 110, protrusionsof an elongated member may be oriented such that an angle between theprotrusions and bottom surface 240 of second end portion 222 is lessthan 90 degrees. For example in FIG. 5, angle 800 between firstprotrusion 225 and bottom surface 240 is approximately 45 degrees. Inother embodiments, angle 800 between first protrusion 225 and bottomsurface 240 may vary in the range of approximately 10 degrees and 80degrees. Also, in FIG. 5, the angle between second protrusion 226 andbottom surface 240 is generally similar to the angle between firstprotrusion 225 and bottom surface 240, and may vary according to thesame range as described for first protrusion 225. However, in otherembodiments, the angle between first protrusion 225 and bottom surface240 may differ from the angle between second protrusion 226 and bottomsurface 240.

Referring to FIGS. 5 and 6, second end portion 222 may have a topsurface 250. Top surface 250 is generally a surface disposed on theopposite side of bottom surface 240. Second end portion 222 has firstthickness 810 extending between top surface 250 and bottom surface 240.Second end portion 222 further has second thickness 820 extendingbetween top surface 250 and first end 227 of first protrusion 225. Firstthickness 810 and second thickness 820 may correspond with depths of arecess configured to receive them, as discussed below. Also, FIG. 5further shows second end portion 222 having tip 228. Tip 228 as shown inFIG. 5 is generally flat. However, in other embodiments, tip 228 couldbe rounded or pointed.

FIG. 6 shows the embodiment of the sole structure 110 shown in FIG. 3,with a cross sectional view of sole structure 110 showing first recess301. As shown in the cross section, first recess 301 includes first endportion 321 and second end portion 322. First end portion 321 isgenerally located on an outer peripheral portion 116 of top surface 111of sole structure. The term “outer peripheral portion” as usedthroughout this detailed description and in the claims refers to an areanear the outer perimeter of top surface 111 of sole structure 110. Itwill be understood that outer peripheral portion 116 is only intendedfor purposes of description and is not intended to demarcate a preciselocation. Generally, first end portion 321 of first recess 301 has ashape corresponding to first end portion 221 of first elongated member201. For example, first end portion 321 of first recess 301 is generallyround which corresponds to a rounded shape of first end portion 221 offirst elongated member 201, as shown in FIGS. 4 and 5. First end portion321 of first recess 301 is generally configured to receive at least someportion of first end portion 221 of first elongated member 201.

FIG. 6 further shows second end portion 322 of first recess 301. Secondend portion 322 of first recess 301 is generally located on an interiorportion 117 of top surface 111 of sole structure 110. The term “interiorportion” as used throughout this detailed description and in the claimsrefers to the central area of top surface 111 of sole structure 110, oran area disposed inwardly of outer peripheral portion 116. Generally,second end portion 322 of first recess 301 has a shape corresponding tosecond end portion 222 of first elongated member 201. For example, asshown in FIG. 6, second end portion 322 of first recess 301 includesfirst notch 325 and second notch 326. In some embodiments, first notch325 and second notch 326 generally have a shape corresponding to firstprotrusion 225 and second protrusion 226 of first elongated member 221,respectively.

Second end portion 322 also includes bottom surface 340. Bottom surface340 extends between first notch 325 and second notch 326, and alsoextends between second notch 326 and first end portion 321. The angle(not shown) between first notch 325 of first recess 301 and bottomsurface 340 of first recess 301 is configured to be similar to angle 800between first protrusion 225 and bottom surface 240 of first elongatedmember 201. Further, the angle (not shown) between second notch 326 offirst recess 301 and bottom surface 340 of first recess 301 is generallysimilar to the angle between second protrusion 226 and bottom surface340 of first elongated member 201. First notch 325 and second notch 326are configured to receive first protrusion 225 and second protrusion226, respectively.

As seen in FIG. 6, second end portion 322 has a first depth 910extending from bottom surface 340 of second end portion 322 to topsurface 111 of sole structure 110, and a second depth 920 extending fromfirst end 327 of first notch 325 to top surface 111 of sole structure110. Generally, first depth 910 of first recess 301 and second depth 920of first recess 301 are substantially similar to first thickness 810 ofsecond end portion 222 and second thickness 820 of second end portion222 (see FIG. 5), respectively. Accordingly, when first elongated member201 is disposed in first recess 301, second end portion 222 of firstelongated member 201 is disposed within second end portion 322 of firstrecess 301 such that top surface 250 of first elongated member 201 issubstantially co-planar, or flush, with top surface 111 of solestructure 110. The term “co-planar” as used in this detailed descriptionand in the claims refers to two or more surfaces disposed on the sametwo-dimensional plane. In other embodiments, top surface 250 of firstelongated member 201 may not be co-planar with respect to top surface111 of sole structure 110. For example, first thickness 810 could begreater than first depth 910 so that top surface 250 of first elongatedmember 201 is elevated with respect to top surface 111 of sole structure110. Alternatively, first depth 910 could be greater than firstthickness 810 so that top surface 111 of sole structure 110 is elevatedwith respect to top surface 250 of first elongated member 201.

FIG. 7-10 illustrate the assembly or connection of upper 102 to solestructure 110 using using elongated members 200. For purposes ofillustration, some details of upper 102 in FIGS. 7-10 have been omitted.FIG. 7 shows upper 102 having elongated members 200 attached to upper102.

In the exemplary embodiment shown in FIG. 7, upper 102 includes heelstraps 120 on first end 125 of heel portion 14, and apertures 130 onsecond end 135 of heel portion 14. Heel straps 120 are generallyelongated pieces of material that may be used to fasten heel portion 14.In at least some embodiments, heel straps 120 may be formed by athree-dimensional printing process from a printable material; e.g., apolymeric material. In order to enclose heel portion 14, heel straps 120engage apertures 130. In other embodiments, heel straps 120 may bedisposed on second end 135 of heel portion 14, and apertures 130 may bedisposed on first end 125 of heel portion 14.

In FIG. 8, upper 102 and elongated members 200 are arranged for assemblywith sole structure 110. To align elongated members 200 withcorresponding recesses 300, elongated members 200 may oriented so thatthey extend inwardly from the outer peripheral portion 116 of topsurface 111 to the interior portion 117 of top surface 111. For example,tip 228 of second end portion 222 of first elongated member 201 pointsgenerally in a direction toward interior portion 117. Because elongatedmembers 200 are rotatably coupled to cord element 150, each elongatedmember can easily be rotated into a position that aligns the elongatedmember with a corresponding recess on top surface 111.

FIG. 9 shows upper 102 partially connected to sole structure 110 viaelongated members 200. Once elongated members 200 are engaged withrecesses 300, a portion of elongated members 200 are generallyco-planar, or flush, with recesses. For example, in FIG. 9, top surface250 of second end portion 222 of first elongated member 201 isapproximately co-planar with top surface 111 of sole structure 110.

In at least some embodiments, the rounded geometry of first end portion221 of first elongated member 201 may provide a portion of firstelongated member 201 that extends outwardly from first recess 301 whenfirst elongated member 201 is inserted into first recess 301. In otherwords, in some cases, first end portion 221 may not be flush with topsurface 111, while second end portion 222 may generally be flush withtop surface 111. In other embodiments, first end portion 221 could beflattened along top surface 250 of elongated member 201 so that firstend portion 221 is approximately flush with top surface 111 of solestructure 110.

FIG. 10 shows upper 102 with first end 125 of heel portion 14 attachedto second end 135 of heel portion 14 by passing heel straps 120 throughapertures 130. For example, first heel strap 121 first passes throughfirst aperture 131 to help secure first end 125 to second end 135.

FIG. 11 illustrates an isometric exploded view of another embodiment ofan article having an upper 192 coupled to a cord element 194 andelongated members 196. FIG. 11 further includes an enlarged view of oneelongated member 197 and a portion of cord element 194. For purposes ofillustration, a corresponding sole structure is not shown in FIG. 11. Insome embodiments, the corresponding sole structure may be similar insome or all respects to sole structure 110 discussed above and shown inFIGS. 6-9.

In the embodiment of FIG. 11, cord element 194 and elongated members 196may be integrally formed, rather than having elongated members 196separately formed and coupled to cord element 194. For example, anelongated member 197 is seen to be integrally formed with cord element194. Cord element 194 could be further assembled with upper 192 in amanner that allows cord element 194 to at least partially rotate ortwist with respect to upper 192. In some cases, for example, cordelement 194 could be attached to upper 192 using various kinds offasteners that allow for relative movement of cord element 194 and upper192. In one embodiment, for example, cord element 194 could be attachedto upper 192 using clips or bands. Such a configuration might thereforeallow for relative movement of elongated members 196 and upper 192,which facilitates the assembly of elongated members 196 with acorresponding sole structure. For example, upper 192 with cord element194 and elongated members 196 may be assembled with a corresponding solestructure in a substantially similar manner to the assembly of upper 102with sole structure 110 shown in FIGS. 7-10.

The method described in FIGS. 7-10 offer several advantages over otherpossible attachment means (for example, sewing or gluing) of an upper toa sole structure. First, elongated members 200 are “non-destructivelyremovable” from sole structure 110 of article of footwear 100. In otherwords, elongated members 200 may be removed from sole structure 110without destroying, tearing, and/or breaking either upper 102 and/orsole structure 110. This allows components of article of footwear 100 tobe interchangeable. For example, upper 102 may be connected to a newsole structure (not shown) which may replace sole structure 110 thatbecomes damaged. Or, the new sole structure may offer a differentcomfort or feel. Alternatively, sole structure 110 can be attached to anew upper providing a different comfort, feel, and/or aesthetic appeal.Further, using elongated member 200 may decrease the number of distinctmaterials used to manufacture article 100 in contrast to embodimentsthat require thread, glue or other adhesives, thereby reducingmanufacturing costs.

The design of elongated members 200 offers further advantages. Forexample, angle 800 (see FIG. 5) between first notch 225 and bottomsurface 240 of second end portion 222 may be selected according to theoptimal configuration for securing elongated members 200 within recesses300. In other words, first protrusion 225 and second protrusion 226,coupled with first notch 325 and second notch 326, offer a mechanicalconfiguration sufficient to maintain attachment between upper 102 andsole structure 110.

Generally, elongated members 200 are not disconnected from recesses 300unless a wearer manually (and intentionally) disconnects elongatedmembers 200 from recesses 300. When a foot and/or liner is disposedwithin article 100, elongated members 200 may be prevented fromdisconnecting with recesses 300 as the foot and/or liner tends torestrict any vertical movement necessary for removal. Moreover, theprotrusions of elongated members 200 (e.g., first protrusion 225 andsecond protrusion 226) when engaged with notches (e.g., first notch 325and second notch 326) act to restrict horizontal motion of elongatedmembers 200. In particular, as upper 102 pulls or tugs on elongatedmembers 200 in a direction towards outer peripheral portion 116 of solestructure 110, the protrusions help prevent elongated members 200 frombeing pulled out of corresponding recesses 300.

In order to offer additional comfort, in some embodiments an insoleand/or other liner (not shown) may be inserted over top surface 111 ofsole structure after elongated members 200 engage recesses 300.

In another embodiment, an article of footwear may include an upper madefrom a material, such as a textile material or leather material, withthe upper having structures printed onto the upper by athree-dimensional printer. For example, in FIG. 12, upper 402 of articleof footwear 400 (also referred to as simply article 400) includesseveral printed structures 500 printed on the lateral side 16 of upper402 as well as the medial side (not shown) of upper 402. Printedstructures 500 include a first printed structure 501 on lateral side 16of article 500. First printed structure 501 includes extended portions520 and fastener receiving portions 530. As shown in FIG. 12, extendedportions 520 generally extend vertically along upper 402. For example,extended portions 520 include first extended portion 525 and secondextended portion 526. In other embodiments, extended portions 520 mayextend in a non-linear manner, such as a wavy-pattern or a zig-zagpattern. Further, extended portions 520 may be at least partiallyembedded in upper 402 with the embedded portion bonding to individualfibers (not shown) in upper 402. The embedded portion of extendedportions 520 extends below the exterior surface of upper 402, while theremaining non-embedded portion of extended portions 520 extends abovethe exterior surface of upper 402. Moreover, extended portions 520 aregenerally anchored into upper 402 and free from movement. Althoughextended portions 520, as shown in FIG. 12, extend generally alongmidfoot portion 12 of article 400, extended portions 520 may also extendalong forefoot portion 10 and/or heel portion 14.

Fastener receiving portions 530 are generally configured to receive alacing system (not shown), such as shoe laces. As shown in FIG. 12,fastener receiving portions 530 may be looped structures. In someembodiments, fastener receiving portions 530 are at least partiallyembedded in upper 402 with the embedded portion bonding to individualfibers (not shown) in upper 402. In the embodiment shown in FIG. 12,fastener receiving portions 530 are not bonded to upper 402 and are freeto move with a lacing system. In other words, fastener receivingportions 530 may be separated from upper 402. Although not shown,article of footwear 400 includes printed structures 500 having a secondprinted structure on the medial side 18 of article 400. The secondprinted structure may vary in any way described for the first printedstructure 501.

FIGS. 13-14 illustrate another embodiment of elongated members used tosecure or fasten an upper to a sole structure. As shown in FIG. 13,printed structures 500 further include several elongated members 505extending from the lower peripheral portion 407 of upper 402. Elongatedmembers 505 are printed from a printable material that could vary in anymanner as previously described in the earlier embodiment. Generally,elongated members 505 are flexible and can bend and/or twist withouttearing and/or breaking. Although elongated members 505 in FIG. 13 aregenerally shown on lateral side 16 of upper 402, elongated members mayalso be located on forefoot portion 10 and/or heel portion 14.

FIG. 13 further shows elongated members 505 having apertures. Forexample, first elongated member 506 includes first aperture 515. In someembodiments, first aperture 515 may be square or rectangular. In theembodiment shown in FIG. 13, first aperture 515 is generally circular.Also, in other embodiments, first elongated member 506 may furtherinclude a second aperture. Still, in other embodiments, first elongatedmember may further include at least three apertures. First elongatedmember 506 further includes exterior surface 540 and interior surface550 on a surface opposite exterior surface 540. Further, first elongatedmember 506 includes a thickness 850, where thickness 850 extends fromexterior surface 540 to interior surface 550. Thickness 850 may vary inthe range of approximately 0.2 mm to 9 mm.

Also, FIGS. 13-14 illustrate sole structure 410 configured to attach toupper 402. Sole structure 410 includes top surface 411 having recesses600. Sole structure 410 further includes bottom surface 412 disposedopposite of top surface 411. Bottom surface 412 is generally intended tocontact a ground surface (not shown).

Recesses 600 are disposed on top surface 411, and are configured toreceive elongated members 505. For example, first recess 601 of recesses600 may be configured to receive first elongated member 506. Referringto FIG. 14, recesses 600 include at least one protrusion. For example,first recess 601 includes first protrusion 615.

Recesses 600 may be further arranged such that a first end of eachrecess is disposed in an outer peripheral portion of top surface 411,while a second end of each recess is disposed in an interior portion oftop surface 411. For example, as shown in FIG. 14, first recess 601 hasa first end portion 621 disposed in outer peripheral portion 516 of topsurface 411. First recess 601 also has second end portion 622 disposedin interior portion 517 of top surface 411.

In order to secure upper 402 to sole structure 410, elongated members505 are configured to bend inward toward interior portion 517 of topsurface 411 of sole structure 410. For example, first elongated member506 may bend with respect to an extended portion 513 at bending portion512. Then, recesses 600 engage elongated members 505. For example, asshown in FIGS. 13 and 14, first protrusion 615 is configured to engagefirst aperture 515 of first elongated member 506. First protrusion 615,as shown in FIG. 14, is generally cylindrical. However, in otherembodiments, first protrusion 615 may have a square or rectangular crosssection. Generally, first protrusion 615 has a cross section that issubstantially similar in size and shape to aperture 515 of firstelongated member 506. Also, in other embodiments, first recess 601 mayfurther include a second protrusion. Still, in other embodiments, firstrecess 601 may further include at least three protrusions. Although thenumber of protrusions may vary, the number of protrusions in firstrecess 601 may generally be similar to the number of apertures on firstelongated member 506.

Referring again to FIG. 14, first recess 601 includes first depth 950.First depth 950 extends from bottom surface 640 of first recess 601 totop surface 411 of sole structure 410. Although first depth 950 mayvary, first depth 950 is generally at least as large as thickness 850 offirst elongated member 506. In some embodiments, first depth 950 issubstantially similar to thickness 850. For example, in the embodimentshown in FIG. 13, thickness 850 is generally similar to first depth 950,and accordingly, when exterior surface 540 of first elongated member 506engages bottom surface 640 of first recess 601, interior surface 550 offirst elongated member 506 may be generally co-planar, or flush, withtop surface 411 of sole structure 410. In other embodiments, interiorsurface 550 of first elongated member 506 may not be co-planar with topsurface 411 of sole structure 410. For example, thickness 850 could begreater than first depth 950 so that interior surface 550 of firstelongated member 506 is elevated with respect to top surface 411 of solestructure 410. Alternatively, first depth 950 could be greater thanthickness 850 so that top surface 411 of sole structure 410 is elevatedwith respect to interior surface 550 of first elongated member 506.

In some embodiments, some of the components comprising the articlesdescribed above and shown in FIGS. 1-14 may be formed using athree-dimensional printer. However, in other embodiments, thesestructures could be manufactured by means other than a three-dimensionalprinter. For example, other embodiments could use injection molding.Further, attachment means (of elongated members to an upper) couldinclude ultrasonic welding or radio frequency welding in order to createan upper having attached portions and fastener receiving portions.

FIG. 15 illustrates three-dimensional printer 1000. Three-dimensionalprinter 1000 could be, for example, a MakerBot® Replicator™ 2.Three-dimensional printer 1000 is connected to a power source (notshown) in order to supply a current to three-dimensional printer 1000.Three-dimensional printer 1000 further includes print head 1010 capableof moving in three dimensions and disposing a printable material to forma three-dimensional object, including an upper or other portions of anarticle. In the embodiment shown in FIG. 15, print head 1010 is capableof delivering first printable material 1011 and second printablematerial 1012 onto a surface 1030 of three-dimensional printer 1000 inorder to form portions of an article. In other embodiments, a firstprint head and a separate second print head are used to dispose a firstprint substance 1011 and a second print substance 1012, respectively,onto surface 1030.

FIGS. 16-18 illustrate upper 102 and elongated members 200 being printedin three-dimensional printer 1000. Three-dimensional printer 1000 iscapable of printing multiple printable materials of varying densitiesand strengths. For example, first printable material 1011 could have afirst density and first tensile strength, and second printable material1012 could have a second density and second tensile strength. In someembodiments, first printable material 1011 has a higher density andhigher tensile strength than second printable material 1012. In theembodiment shown in FIGS. 16-18, second printable material 1012 has ahigher density and higher tensile strength than first printable material1011. It should be understood a more dense printable material or aprintable material having a higher tensile strength may create a morerigid structure made to additionally resist tearing, breaking, bending,and/or deforming. As used herein, the density of first printablematerial 1011 and second printable material 1012 refer to densities ofthese materials in a cured state.

FIG. 16 shows a portion of upper 1102 printed in three-dimensionalprinter 1000. Three-dimensional printer 1000 uses first printablematerial 1011 to print upper 1102. In other embodiments, upper 1102 ismade from second printable material 1012. Still, in other embodiments,upper 1102 could be made from a combination of first printable material1011 and second printable material 1012.

As shown in FIG. 17, a cord element 194 with integrally formed elongatedmembers 196 may be printed using three-dimensional printer 1000. Asshown in FIG. 17, in some embodiments, cord element 194 and elongatedmembers 196 are printed with second printable material 1012. In someother embodiments, cord element 194 and elongated members 196 areprinted with first printable material 1011. Still, in other embodiments,cord element 194 and elongated members 196 could be printed with acombination of first printable material 1011 and second printablematerial 1012.

In FIG. 18, cord element 194 with integrally formed elongated members196 may be coupled with upper 1102. This coupling may be achieved usingany means known in the art, and in at least some cases may be selectedso that cord element 194 and elongated members 196 can move related toupper 1102 (e.g., via rotation or twisting).

As indicated schematically in FIG. 18, upper 1102 is formed from firstprintable material 1011, while cord element 194 and elongated members196 are formed from second printable material 1012. As discussed above,in at least some embodiments, first printable material 1011, when cured,may be less rigid than second printable material 1012. Thisconfiguration may allow for upper 1102 to stretch and flex around afoot, while cord 194 and elongated members 196 may generally resiststretching in order to maintain a strong connection with a correspondingsole structure.

Several other possible configurations for coupling elongated members andan upper, during or after printing of these components are possible. Inone embodiment, elongated members with apertures for receiving a cordcould be printed separately from the cord and the upper, and at a latertime coupled to the cord (e.g., by inserting the cord through theapertures of the elongated members). Then, the cord and elongatedmembers could be further assembled with the printed upper.

It is contemplated that in at least one embodiment, the process ofprinting may include separately printing an upper, a cord and elongatedmembers. Then, after printing each component separately, the elongatedmembers could be coupled to the cord (e.g., by passing the cord throughapertures of the elongated members). The assembled cord and elongatedmembers could then be further coupled to the upper. Optionally, a cordmay not be printed, but could be assembled with elongated members and/oran upper after the upper and elongated members have been separatelyprinted.

As already discussed, elongated members may be configured as mechanicalconnectors in at least some embodiments. In particular, elongatedmembers may also be referred to as mechanical connectors when theelongated members have provisions for engaging recesses in a solestructure.

FIGS. 19 and 20 illustrate an embodiment of a method of forming theupper and elongated members for article of footwear 400 usingthree-dimensional printer 1000, which is discussed above and shown inFIGS. 12-14. As shown in FIG. 19, upper 402 may be associated withsurface 1030 during a first step. Optionally, in some cases, upper 402could be printed using three-dimensional printer 1000 prior to the stepshown in FIG. 15. However, in other cases, upper 402 could bemanufactured from a textile or other material known in the art formaking uppers.

With upper 402 in place, three-dimensional printer 1000 may beginprinting a printable material 1011 onto upper 402. In FIG. 19, printhead 1010 has already printed a first printed structure 1150 on one sideof upper 402. In the embodiment of FIG. 19, print head 1010 prints anextended portion 1120 and a fastener receiving portion 1122. Inaddition, print head 1010 prints a first end portion 1132 of anelongated member 1130 directly onto lower peripheral portion 407 ofupper 402. Elongated member 1130 may be configured to engage a recess ina sole structure, and therefore elongated member 1130 may be amechanical connector.

Next, as shown in FIG. 20, print head 1010 continues printing a secondend portion 1134 of elongated member 1130. Here, second end portion 1134is printed in a manner such that second end portion 1134 is connected tofirst end portion 1132, but second end portion 1134 is not directlyconnected to lower peripheral portion 407. Instead, second end portion1134 extends away from lower peripheral portion 407. In at least someembodiments, elongated member 1130 is printed to have an aperture thatcan engage a protrusion in a corresponding recess on a sole structure,as discussed previously and shown in FIGS. 13 and 14.

Following this, print head 1010 may continue to print additionalextended portions, fastener receiving portions and elongated members ofa second printed structure 1152. As discussed above, each elongatedmember may be a mechanical connector. For example, elongated member 1130is a mechanical connector that is configured to connect to an associatedsole structure (e.g., sole structure 410 of FIG. 13). Moreover, theprinted mechanical connectors, which have been printed directly to upper402, may engage recesses 600 in sole structure 410 to facilitateassembly of article of footwear 400 (see FIG. 13).

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Accordingly, the embodiments are not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

What is claimed is:
 1. An article of footwear, comprising: an upperhaving a lower peripheral portion, wherein the upper includes anelongated member extending from the lower peripheral portion; a solestructure having a top surface and an opposing bottom surface, whereinthe top surface is disposed closer to the upper than is the bottomsurface; the sole structure including a recess disposed in the topsurface and extending below the top surface toward the bottom surface;the top surface of the sole structure further including an interiorportion, and also including an outer peripheral portion disposedoutwardly of the interior portion; wherein the recess includes a firstend portion disposed on the outer peripheral portion of the top surface,and a second end portion disposed on the interior portion of the topsurface; wherein the elongated member includes a first end portion and asecond end portion; wherein the first end portion of the elongatedmember engages the first end portion of the recess and the second endportion of the elongated member engages the second end portion of therecess; and wherein the upper includes a cord element coupled with andextending along the lower peripheral portion of the upper, and whereinthe elongated member is attached to the cord element.
 2. The article offootwear according to claim 1, wherein the elongated member includes anaperture and wherein the cord element is disposed through the apertureof the elongated member.
 3. The article of footwear according to claim1, wherein: the second end portion of the elongated member includes eachof a first protrusion and a second protrusion; wherein the second endportion of the recess includes each of a first notch and a second notch;wherein the first protrusion engages the first notch; and wherein thesecond protrusion engages the second notch.
 4. The article of footwearaccording to claim 3, wherein the second end portion of the elongatedmember includes at least a third protrusion, and wherein the second endportion of the recess includes at least a third notch.
 5. The article offootwear according to claim 3, wherein the second end portion of theelongated member comprises a top surface, and wherein the top surface ofthe second end portion is co-planar with the top surface of solestructure when the elongated member is engaged with the recess.
 6. Thearticle of footwear according to claim 1, wherein the upper furthercomprises at least one mesh portion.
 7. The article of footwearaccording to claim 6, wherein the mesh portion is formed of a curedpolymeric material suitable for dispensing from a three-dimensionalprinter when in an uncured state.
 8. The article of footwear accordingto claim 1, wherein the elongated member is formed of a cured polymericmaterial suitable for dispensing from a three-dimensional printer whenin an uncured state.
 9. An article of footwear, comprising: an upperhaving a lower peripheral portion, wherein the upper includes anelongated member extending from the lower peripheral portion; a solestructure having a top surface and an opposing bottom surface, whereinthe top surface is disposed closer to the upper than is the bottomsurface; the sole structure including a recess disposed in the topsurface; the top surface of the sole structure further including aninterior portion, and also including an outer peripheral portiondisposed outwardly of the interior portion; wherein the recess includesa first end portion associated with the outer peripheral portion of thetop surface, and the recess includes a second end portion associatedwith the interior portion of the top surface; wherein the elongatedmember includes a first end portion, and the elongated member includes asecond end portion; wherein the first end portion of the elongatedmember engages the first end portion of the recess, and the second endportion of the elongated member engages the second end portion of therecess; wherein the upper includes a cord element coupled with andextending along the lower peripheral portion of the upper, and whereinthe elongated member is attached to the cord element.
 10. The article offootwear according to claim 9, wherein the elongated member includes anaperture and the cord element is disposed through the aperture of theelongated member.
 11. The article of footwear according to claim 9,wherein the second end portion of the elongated member includes each ofa first protrusion and a second protrusion; wherein the second endportion of the recess includes each of a first notch and a second notch;wherein the first protrusion engages the first notch; and wherein thesecond protrusion engages the second notch.
 12. The article of footwearaccording to claim 11, wherein the second end portion of the elongatedmember includes at least a third protrusion, and the second end portionof the recess includes at least a third notch.
 13. The article offootwear according to claim 11, wherein the second end portion of theelongated member comprises a top surface, and the top surface of thesecond end portion is co-planar with the top surface of sole structurewhen the elongated member is engaged with the recess.
 14. The article offootwear according to claim 9, wherein the upper further comprises atleast one mesh portion.
 15. The article of footwear according to claim14, wherein the mesh portion is formed of a cured polymeric materialsuitable for dispensing from a three-dimensional printer when in anuncured state.
 16. The article of footwear according to claim 9, whereinthe elongated member is formed of a cured polymeric material suitablefor dispensing from a three-dimensional printer when in an uncuredstate.
 17. An article of footwear, comprising: an upper having a lowerperipheral portion, wherein the upper includes an elongated memberextending from the lower peripheral portion; a sole structure having atop surface and an opposing bottom surface, wherein the top surface isdisposed closer to the upper than is the bottom surface; the solestructure including a recess disposed in the top surface; the topsurface of the sole structure further including an interior portion, andalso including an outer peripheral portion disposed outwardly of theinterior portion; wherein: the recess includes a first end portionassociated with the outer peripheral portion of the top surface and asecond end portion associated with the interior portion of the topsurface; the elongated member includes a first end portion and a secondend portion; the first end portion of the elongated member engages thefirst end portion of the recess and the second end portion of theelongated member engages the second end portion of the recess; thesecond end portion of the elongated member includes each of a firstprotrusion and a second protrusion; the second end portion of the recessincludes each of a first notch and a second notch; the first protrusionengages the first notch; the second protrusion engages the second notch;the second end portion of the elongated member comprises a top surface;and the top surface of the second end portion is co-planar with the topsurface of the sole structure when the elongated member is engaged withthe recess.